Method of making wheel covers



Sept. 25, 1962 G. A. LYON METHOD OF MAKING WHEEL COVERS 4 Sheets-Sheet 1 v Filed Feb. 21, 1957 hVE'IZ/EF G'EORGE /74 85/? r A You El /g5.

Sept. 25,1962 '6. A. LYON 3,055,330

METHOD OF MAKING WHEEL COVERS Filed Feb. 21, 1957 4 Sheets-Sheet 2 [D an/UP GEORGE flLBERrLm/V Sept. 25, 1962 e. A. LYON 3,055,330

METHOD OF MAKING WHEEL COVERS Filed Feb. 21, 1957 4 Sheets-Sheet 3 G. A. LYON Sept. 25, 1962 1 527 far GEORGE fiLBfRT Ara/V I fill/1:75.

United fltates Eatent 3,055,330 METHOD OF MAKING WHEEL COVERS George Albert Lyon, Detroit, Mich., assignor to Lyon Incorporated, Detroit, Mich., a corporation of Delaare Filed Feb. 21, 1957, Ser. No. 641,548 3 Claims. (Cl. 113116) The present invention relates to improvements in the manufacture of wheel covers of the kind that are adapted to be applied in press-on, pry-ofi relation to the outer sides of vehicle wheels.

An important object of the present invention is to provide an improved method of making wheel covers of the kind that have marginal self-retaining fingers as extensions from a generally axially inwardly extending underturned marginal flange.

Another object of the invention is to provide an improved method of providing the marginal retaining flange structure of wheel covers with a reinforcing rib and seating shoulder structure.

A further object of the invention is to provide an improved method of shaping a reinforcing and seating shoulder in an axial marginal retaining means flange of and otherwise preformed wheel cover.

Other objects, features and advantages of the present invention will be readily apparent from the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings in which:

FIGURE 1 is an outer side elevational view of a wheel structure embodying features of the invention;

FIGURE 2 is an enlarged fragmentary radial sectional detail view taken substantially on the line II-II of FIG- URE 1;

FIGURE 3 is a fragmentary radial sectional view through a wheel cover blank in a partial stage of formation;

FIGURE 4 is a sectional view similar to FIGURE 3 but showing the cover blank in a further stage of formation;

FIGURE 5 is a sectional view similar to FIGURES 3 and 4 but showing the cover blank in a succeeding stage of formation;

FIGURE 6 is a sectional view similar to FIGURE 5 but showing the cover blank after another step in the method of making the same;

FIGURE 7 is a fragmentary vertical sectional detail view through apparatus in which the marginal retaining means flange of the cover is adapted to be Worked to provide a stepped shoulder therein, and showing the apparatus in an operating condition;

FIGURE 8 is a fragmentary sectional elevational detail view showing roller die means of the apparatus to effect a final forming operation; and

FIGURE 9 is a sectional view similar to FIGURE 7 but showing the shoulder forming die apparatus in the open, cover-releasing condition thereof.

Referring first to FIGURES 1 and 2, a wheel cover 10 made according to the method of the present invention is adapted to be applied to the outer side of a vehicle wheel of more or less conventional form including a disk spider wheel body 11 supporting a multi-flange, drop center tire rim 12 provided with an intermediate generally axially outwardly extending and slightly radially outwardly sloping flange 13 which merges at a shoulder 14 with a generally radially outwardly and then axially outwardly turned terminal flange 15. A pneumatic tire 17 is adapted to be supported by the tire rim.

The cover 10 is of the full disk type, that is it is of a diameter to substantially completely overlie the wheel inclusive of the wheel body 11 and the tire rim 12. Centrally, the cover 10 comprises a crown portion 18 which ice slopes substantially radially outwardly and axially inwardly into an intermediate annular deeply dished portion 19 from which extends generally radially and axially outwardly a marginal portion 20. For both reinforcement and ornamental effect, the dished intermediate portion 19 of the cover is provided with a plurality of pressed up ribs 21 of generally spoke-like form which merge at their respective opposite ends with the upper portion of the crown and with the marginal flange portion 20, respectively.

At its outer extremity, the cover marginal portion 211 is provided with a reinforcing rib 22 which is adapted to overlie the tip of the terminal flange 15 of the tire rim in spaced or gap relationship whereby freely to accommodate the clips of Wheel balancing weights which are commonly supported by the terminal flange. Further reinforcing the annular marginal cover portion 20* is an integral underturned flange 23 which snugly, nestingly engages the inner side of the radially outer section of the marginal portion 20.

For retaining the cover on the wheel in press-on, pryoif relation, the underturned marginal flange 23 is provided with a generally axially inwardly extending flange portion 24 of substantial width provided with retaining finger extensions 25 on the axially inner extremity there of. Each of the retaining fingers has a short and stiff generally radially and axially outwardly oblique retaining terminal 27 which is engageable in direct edgewise retaining gripping engagement with the radially inner face of the intermediate flange 13. Resilient tensioned grip of the retaining terminals 27 is afforded by havng the retaining fingers normally extending to a diameter wherein the tips of the terminals 27 are on a larger diameter than the engaged diameter of the intermediate flange 13, so that as the cover is pressed axially inwardly to apply the same to the wheel the retaining fingers 25 are placed under resilient radially inward deflectional tension.

To maintain the marginal portion 20 and the underturned flange 23 in axially outwardly spaced relation to the terminal flange, the axially extending flange 24 is provided intermediately thereof with an annular generally stepped reinforcing and seating flange shoulder portion 28. Thereby the portion of the flange 24 axially inwardly from the shoulder 28 is radially inwardly inset to a slightly smaller diameter than the axially outer portion of the intermediate flange 13, while the portion of the flange 24 axially outwardly from the shoulder 28 is radially outwardly offset to a larger diameter than the intermediate flange 13, and the shoulder 28 is adapted in assembly of the cover with the wheel to seat upon the juncture shoulder 14 between the intermediate flange 1G and the terminal flange 15 of the tire rim. It will be observed that the insetting shoulder 28 is disposed on a slanting angle obliquely generally radially and axially inwardly so that it has in addition to the seating function,

a centering function by virtue of its generally frustoconical form so that it has a generally wedging coaction with the rounded rim shoulder 14. This is also a valuable feature in service since it tends to afford a shock absorbing cushion for the cover during transverse jarring or road shocks. During very severe road shocks it will be observed that the axially inner portion of the flange 24 is close enough to the intermediate flange 13 to contact the same after only a slight transverse shifting or resiliently yielding movement. Furthermore, the shoulder 28 serves as a substantial reinforcement for the retaining fingers since it substantially stiffens the flange 24. Moreover, the shoulder 28 serves as a convenient pry-ofl. shoulder when it is desired to remove the cover from the wheel.

In the main the method of making the wheel cover 10 may follow substantially the steps of the method as covered in my Patent 2,707,449 issued May 3, 1955. To

this end, a sheet metal blank of suitable material such as stainless steel, brass, or the like suitable for cold drawing is initially drawn as shown in FIGURE 3 to provide the crown portion 18, the intermediate annular dished portion 19, and the marginal portion in an initial primarily axially outwardly extending shape merging into an annular axially outwardly projecting rib R from which extends a flat marginal flange F comprising the marginal portion of the blank. The flange F is then trimmed to provide outline for the retaining fingers, whereafter the flange F is turned into axially inward position as shown in FIGURE 4 where it is substantially cylindrical and the retaining fingers and the terminal flanges 27 thereof are formed as continuations of the flange. It will be observed that at this stage the axial flange F and the marginal portion 20 provide spaced legs of the rib R.

Then, the rib R is collapsed and turned generally radially outwardly into the position shown in FIGURE 5 wherein the marginal portion 20 is worked down to extend more nearly radially outwardly and the reinforcing edge structure 22 is provided while the underturned flange 23 is disposed in reinforcing laminar relation to the inner side of the marginal cover portion 20. The remainder of the flange F now provides the axially extending flange portion 24 which at this time is of substantially straight cylindrical form and with the marginal portion 20 and the adjacent area of the dished portion 19 of the cover diverging from the flange 24. It will be observed that the dished intermediate portion 19 is now in substantially spaced radially inward relation to the axially extending flange 24 and is thus substantially clear for any additional working thereof and for adequate support thereof in a polishing and bufling fixture. In this condition, therefore, the outer face of the cover 10 is subjected to polishing and bufling since all contours are symmetrically circular. Thereafter, the ribs 21 are pressed in the dished intermediate portion 19 by working the material in reverse from the deep draw thereof. This can be readily effected without substantially disturbing the polished condition of the outer face surfaces of the intermediate portion of the cover. At the conclusion of the ribbing operation, the cover blank appears as in FIGURE 6.

The now partially completed cover 10 is then further worked to form the inset, reinforcing shoulder 28 in the flange 24. This is effected in the forming die apparatus of FIGURES 7-9. In this die apparatus the cover blank is set in generally nested relation with the radially outer portion of the intermediate dished cover portion 19 resting upon complementary oblique radially and axially outwardly slanted supporting surfaces 29 of cam die members 30 (FIG. 7) which may be in a set of three or more supported reciprocably upon a bed 31 and having depending lugs 32 upon which respective return springs 33 are operable normal to drive the cam die members 30 into retracted or backed off position (FIG. 9).

Forming nose portions 34 upon the upper radially outer margins of the cam die members 30 oppose the radially inner side of the axially extending marginal cover flange 24. It will be noted that the outer contour of the forming nose portion 34 of each of the die members 30 is complementary to the shape to be assumed by the inner surface of the inset and offset portions of the flange 24 and the shoulder 28, the nose portion 34 being for this purpose provided with a shoulder-forming undercut surface 35 which is of oblique angularity at no less an angle to the horizontal than the surfaces 29.

Engageable with the outer face of the cover 10 is a hold down and centering reciprocable die member 37 having the surface thereof contoured complementary to the outer face of the cover and intimately engageable therewith as best seen in FIGURE 7. Hold down stroke movement of the die member 37 is coordinated with a driving cam member '38 which is reciprocable in a central cavity or bore 39 in the bed or base member 31 and has a generally frusto-conical actuating cam head 40 which is engageable with complementary cam tail portions 41 on the inner peripheries of the cam die members 30 to shift the cam die members radially outwardly against the action of the return spring 33 until the cam die noses 34 engage the inner surface of the cover flange 24. When the cam die members 30 have reached the limit of their protraction or cover flange engaging stroke, as may be determined by any suitable stop means (not shown) for the driving cam member 38, or by a stop shoulder 42 provided by the bed member 31, or a combination of such stops, the cover 10 is adapted to be placed thereon with the straight flange 24 engaged about the die noses 34 as shown in dash outline in FIGURE 7. Then the hold down die member 37 is clampingly moved against the outer face of the cover.

Following this, the cover flange 24 is shaped by the shaping means 43 which includes a shaping roller 44 having a shaping perimeter portion 45 which is complementary to the shaping undercut 35 of the cam die members and has a contour corresponding to the preferred contour of the seating and reinforcing shoulder 28. The roller 44 is supported in suitable manner as by means of a journal yoke 47 for free rotation. Reciprocal movement of the yoke 47 to drive the roller 44 into cover flange working position and then to a retracted position may be effected by means such as a fluid operated cylinder and piston device 48. A supporting structure 49 not only supports the roller die mechanism but also provides a reciprocable guideway which may be in the form of a keyway or guide slot 50 in which is slidably accommodated a key or slide portion 51 depending from the lower portion of the yoke 47.

In operation, the forming roller 44 is driven radially inwardly against the flange 24 until the flange is bent from the dash line position shown in FIGURE 7 to the full line position wherein the roller periphery 45 coacts with the undercut forming shoulder 35 of the cam dies to shape the shoulder 28 and inset the axially inner portion of the cover flange 24 and the retaining fingers 25. It will be understood that as the roller 44 drives against the cover flange the roller die mechanism 43 and the cam die and hold down die assembly are relatively rotated so that the roller periphery 45 makes rolling contact with the cover flange 24. In order to minimize wrinkling of the flange 24 as it is worked by the roller periphery 45, the roller is driven gradually or progressively toward and in working relation against the flange 24 as the relative turning, rolling action takes place at fairly high speed. To elfect the rolling action either the supporting structure 49 may be turned about the supporting bed 31, or the supporting bed 31 and the hold down die member 37 may be rotated relative to the supporting structure 49. The radially inward thrusting movement of the roller 44 and the relative turning of the die mechanisms continues until the shoulder 28 has been fully rolled into the flange By preference, the width of the forming perimeter 45 of the roller 44 is only such as to form the shoulder 28, while the portion of the flange 24 axially inwardly from the shoulder, and the retaining fingers 25 are left relatively free for strain relief. This results in the axially inner portion of the flange 24 and the retaining fingers 25 assuming a generally radially outwardly angled position, substantially as shown in full outline in FIGURE 7. Therefore, a final shaping roller die mechanism 52 (FIG. 8) is operated to complete the shaping of the cover flange and finger structure. This roller die mechanism may be substantially like the roller die means 43 and may, if preferred, be supported by the supporting structure 49 for operation in coordinated or timed sequence with the roller die mechanism 43. To this end, the roller die apparatus 52 includes a shaping roller 53 having a shaping periphery 54 complementary to and thrustable toward a complementary shaping surface 55 on the cam die memr bers 30 below the undercut forming surface 35. A supporting journal yoke 57 carries the shaping roller 53 while a slide or key member 58 on the lower portion of the yoke member riding in a radial keyway or groove 59 guides the roller mechanism reciprocably. A fluid-actuated operating device (not shown) may be provided for actuating the roller 53, similarly as the roller 44. Thus, after the roller 44 has completed its rolling operation, or at least after it has substantially completed its rolling operation, the roller 53 is brought into operation to complete the insetting of the axially inner portion of the cover flange 24 and the retaining fingers 25 by rolling the same radially inwardly against the forming surface 55 which is preferably slightly more obliquely angled radially and axially inwardly than the ultimate position of the retaining fingers desired so that when the retaining fingers are released from the rolling pressure of the roller perimeter 54, the fingers will assume or spring to the desired diameter.

After the shaping rollers 44 and 53 have been retracted or backed off from the shaped cover flange 24, and clear of the retaining finger terminal flanges 27, the hold down die member 37 is retracted and backed away from the cover. However, up to this point the cover is still locked against removal by engagement of the forming nose portions 34 of the cam dies over the shoulder 28. Unlocking is effected by retracting the die members 30 by backing off the cam member 39 and permitting the return springs 33 to retract and return the cam die members 30, thus withdrawing the nose portions 34 of the cam dies from the pocket above the flange shoulder 28 and raising the completed cover upon the oblique, cam surfaces 29 of the cam dies into a convenient position to be lifted out of the die mechanism. This position is shown in FIGURE 9.

It will be understood that modifications and variations may be effected without departing from the scope of the novel concepts of the present invention.

I claim as my invention:

1. In a method of making wheel covers, shaping a sheet metal blank into a circular cover form including a central crown portion and a marginal portion with a deeply drawn intermediate annular dished portion, shaping the marginal extremity of the blank into a generally axially inwardly extending straight flange joining the marginal cover portion on a substantially axially outwardly extending annular rib, providing cover-retaining means on the axially inner portion of said flange, bending said rib laterally and radially outwardly substantially beyond the circle of said flange and collapsing the rib to provide a reinforced cover margin overlying said flange in concealing relation while maintaining said axial flange straight and said intermediate portion substantially clear radially inwardly from the flange inclusive of said axially inner portion of the flange to enable additional working of said intermediate portion, then working said dished portion at spaced intervals into reversely bent generally radially extending ribs that project axially outwardly from said dished portion, and thereafter intermediately bending said axial flange into an intermediate offsetting angular reinforcing and seating shoulder flange portion and insetting the axially inner portion of the flange and said cover-retaining means toward said dished portion.

2. In a method of making wheel covers, shaping a sheet metal blank into a circular cover form including a central crown portion and a marginal portion with a deeply drawn intermediate annular dished portion, shaping the marginal extremity of the blank into a generally axially inwardly extending straight flange joining the marginal cover portion on a substantially axially outwardly extending annular rib, providing cover-retaining means on the axially inner portion of said flange, bending said rib laterally and radially outwardly substantially beyond the circle of said flange and collapsing the rib to provide a reinforced cover margin overlying said flange in concealing relation while maintaining said axial flange straight and said intermediate portion substantially clear radially inwardly from the flange inclusive of said axially inner portion of the flange to enable additional working of said intermediate portion, then working said dished portion at spaced intervals into reversely bent generally radially extending ribs that project axially outwardly from said dished portion, thereafter supporting the cover upon reciprocable segment cam die members and with forming nose portions of the die members projecting toward but normally spaced from the inner side of said axial flange, driving said cam die members into engagement of said forming nose portions thereof with the inner surface of said axial flange, and rolling said flange against said segment die nose portions to shape the flange into relatively offset relation of the axially outer and inner portions thereof with an intermediate angular reinforcing and seating shoulder facing generally axially inwardly and joining said flange portions.

3. In a method of making wheel covers, shaping a sheet metal blank into -a circular cover form including a central crown portion and a marginal portion with a deeply drawn intermediate annular dished portion, shaping the marginal extremity of the blank into a generally axially inwardly extending straight flange joining the marginal cover portion on a substantially axially outwardly extending annular rib, providing cover-retaining means on the axially inner portion of said flange, bending said rib laterally and radially outwardly substantially beyond the circle of said flange and collapsing the rib to provide a reinforced cover margin overlying said flange in concealing relation while maintaining said axial flange straight and said intermediate portion substantially clear radially inwardly from the flange inclusive of said axially inner portion of the flange to enable additional working of said intermediate portion, then working said dished portion at spaced intervals into reversely bent generally radially extending ribs that project axially outwardly from said dished portion, thereafter supporting the cover upon reciprocable segment cam die members and with forming nose portions of the die members projecting toward but normally spaced from the inner side of said axial flange, driving said oam die members into engagement of said forming nose portions thereof with the inner surface of said axial flange, rolling said flange against said segment die nose portions to shape the flange into relatively offset relation of the axially outer and inner portions thereof with an intermediate angular reinforcing and seating shoulder facing generally axially inwardly and joining said flange portions, and withdrawing the segment cam die members from engagement with the shaped flange While the cover remains supported on the cam die members.

References Cited in the file of this patent UNITED STATES PATENTS D. 171,303 Lyon Jan. 19, 1954 1,503,270 Klaus July 29, 1924 1,753,963 Mauser Apr. 8, 1930 2,086,488 Batie July 6, 1937 2,230,560 Clark Feb. 4, 1941 2,689,595 Belada Sept. 21, 1954 2,700,354 Lyon Jan. 25, 1955 2,707,449 Lyon May 3, 1955 2,713,449 Lyon July 19, 1955 2,725,257 Maurer et al Nov. 29, 1955 2,757,977 Lyon Aug. 7, 1956 

